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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2652 (Fuel Charging System - Turbocharger -- F250-F550 Super Duty) >> Removal And Installation >> Turbocharger >> Installation

Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install the coolant outlet tube fitting at the center housing of the turbocharger.
    • Tighten to 22 Nm (16 lb-ft).
  2. Apply clean engine oil to the O-Ring seal and install the turbocharger oil filter.
    • Tighten to 24 Nm (18 lb-ft).
    G00636662Courtesy of FORD MOTOR CO.
  3. Install the turbocharger oil supply tube, first the top of the turbocharger oil supply tube fitting and then to the front of the fitting.
  4. Position the new LH and RH turbocharger inlet pipe clamps on the inlet pipes.
  5. Wipe turbocharger valley clean of all oil and debris.
  6. NOTE: Make sure the spring clip for the coolant outlet tube is on the turbocharger before installing the turbocharger on the engine.
    NOTE: The turbocharger is a tight fit between cowl and injection pump fuel lines but can be installed without removing fuel lines.
    NOTE: Position the turbocharger on locating dowels when installing.

    Using a new gasket, install the turbocharger and the 4 new bolts finger tight.

  7. Position the LH turbocharger inlet pipe and clamp to the turbocharger.
    • Do not tighten at this time.
  8. Position the RH turbocharger inlet pipe and clamp to the turbocharger.
    • Do not tighten at this time.
  9. Tighten the turbocharger bolts to 55 Nm (41 lb-ft) in sequence shown in the illustration.
    Fig 1: Turbocharger Bolts Tightening Sequence
    G07481796Courtesy of FORD MOTOR CO.
  10. NOTE: The LH turbocharger inlet pipe clamp nut should be in vertical position.

    Tighten the LH turbocharger inlet pipe and clamp to 15 Nm (133 lb-in).

  11. NOTE: The RH turbocharger inlet pipe clamp nut should be in vertical position.

    Tighten the RH turbocharger inlet pipe and clamp to 15 Nm (133 lb-in).

  12. Disengage the new exhaust upper downpipe clamp T-bolt and loosely install the clamp on the turbocharger.
  13. Position the exhaust downpipe assembly in the vehicle and hand tighten the exhaust upper downpipe bracket bolt.
    • Do not tighten the exhaust upper downpipe bracket bolt at this time.
    Fig 2: Locating Exhaust Upper Downpipe Bracket Bolt
    G07481793Courtesy of FORD MOTOR CO.
  14. Install the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts and hand tighten.
    • Do not tighten the exhaust lower downpipe-to-catalyst and particulate filter assembly bolts at this time.
    Fig 3: Locating Exhaust Lower Downpipe-To-Catalyst And Particulate Filter Assembly Bolts
    G07481794Courtesy of FORD MOTOR CO.
  15. Tighten the exhaust upper downpipe bracket bolt to 25 Nm (18 lb-ft).
    Fig 4: Locating Exhaust Upper Downpipe Bracket Bolt
    G07481793Courtesy of FORD MOTOR CO.
  16. Engage the new exhaust upper downpipe clamp T-bolt and position the clamp as marked during removal.
    • Tighten to 15 Nm (133 lb-in).
    Fig 5: Locating Exhaust Upper Downpipe Clamp T-Bolt
    G07481792Courtesy of FORD MOTOR CO.
  17. Install the turbocharger heat shield and 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  18. Tighten the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts to 40 Nm (30 lb-ft).
    Fig 6: Locating Exhaust Lower Downpipe-To-Catalyst And Particulate Filter Assembly Bolts
    G07481794Courtesy of FORD MOTOR CO.
  19. Install the RH fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
  20. Position the coolant outlet tube and install it into the turbocharger spring clip fitting.
  21. If equipped, connect the turbocharger wastegate actuator vacuum hose.
  22. Connect the turbocharger actuator electrical connector.
  23. NOTE: Lubricate the O-ring seal with engine coolant.

    Install the heater core inlet tube and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
  24. Connect the heater core inlet hose to the heater inlet tube.
  25. Inspect the Charge Air Cooler (CAC) and CAC  tubes for metal particles. Carry out the Charge Air Cooler (CAC) Cleaning. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
  26. Install the lower intake manifold. For additional information, refer to ENGINE MECHANICAL - 6.7L DIESEL .
  27. Remove and discard the engine oil filter.
  28. Drain the engine oil by turning the oil pan drain plug one quarter turn Counterclockwise (CCW).
    • Install the engine oil pan drain plug and tighten one quarter turn Clockwise (CW).
  29. NOTE: Lubricate the engine oil filter seal with clean engine oil.

    Install a new engine oil filter.

    • Tighten to 5 Nm (44 lb-in) then an additional 180 degrees.
  30. Fill the engine with the correct motor oil for the climate. For additional information, refer to Description and Operation in ENGINE MECHANICAL - 6.7L DIESEL .
  31. Connect the battery ground cable. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES .
  32. Evaluate the primary cooling system. For additional information, refer to Cooling System Condition Evaluation in ENGINE COOLING - DIESEL ENGINE .
  33. Perform the cooling system pressure test. For additional information, refer to ENGINE COOLING - DIESEL ENGINE .
  34. NOTE: This step is required only when a new turbocharger is being installed.

    After the new turbocharger is installed, using a diagnostic scan tool, perform the following:

    • Reset/clear the specified function for the turbo system.
    • Clear the continuous PCM DTC's and reset the emissions monitors information in the PCM. Refer to Powertrain Control/Emissions Diagnosis (PC/ED) information.
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